Cross Bar Support For Use With Storage Racks

ABSTRACT

A cross bar for bearing a load across horizontal supports in a storage system, the cross bar having generally flat members with a plurality of openings and a transition section between the first and second generally flat members, with optional engagement means at a first and second end of the cross bar.

BACKGROUND

The embodiments herein relate generally to a system for providing an economic and effective support for large volume stackable items, such as boxes of hard copy files.

For many years, boxes have been stored on steel shelving designed to accommodate loads particular to boxes of files, as well as other items having similar space and/or weight constraints. Numerous types of shelving supports have been used in the past and are used presently, from corrugated sheets to discrete cross bars that span across support beams. The beams may be placed spaced apart or adjacent. Several configurations of discrete cross bars are exemplified by those shown in FIG. 1 herein. They consist generally of U-shaped and C-shaped bars of varying thicknesses and varying web and flange dimensions (depending upon the specified load).

Often, a storage rack system consists of posts and support beams, where the support beams span the posts to support the shelving. In some cases, the support beams include slots or holes to permit secure engagement of the shelving supports to the support beams, as shown in certain embodiments of FIG. 1. Such engagement minimizes movement of the shelving support as items such as boxes are placed, moved or removed from the shelving support. To accommodate engagement, the shelving may include tabs at their ends to fit into the slots or holes in the support beams, as reflected in some of the prior art embodiments of FIG. 1.

While the available cross bars of today work generally effectively, they are lacking in certain respects, whether it be weight-related or cost-related. Many present cross bars are not economic to manufacture because they require a relatively large amount of material to withstand the load intended. With the cost of metal material continuing to rise, a more economic cross bar design is needed. Embodiments of the present invention solve at least this problem.

SUMMARY

In one embodiment of the present invention, a cross bar is provided for bearing a load across a span of distance between at least two horizontal supports in a storage system. The cross bar comprises first and second generally flat members each comprising a first surface configured to accept the placement of items for storage thereon. A transition section is provided between the first and second generally flat members, where the transition section is defined by a generally flat second surface positioned generally within a plane that is generally parallel to and spaced from the first surface of each of said generally flat members. The first and second flat members each comprise a plurality of slotted openings that may be defined by ridges depressed downwardly from the first surfaces surrounding each of said openings.

In one embodiment, tabs are provided at a first and second end of the cross bar, where the tabs are configured to mate with corresponding openings in supports within the storage rack system. The tabs may be positioned within or adjacent to the transition section. In another embodiment, pilot holes are provided at the first and second ends of the cross bar, preferably in the second surface of the transition section, where a mechanical connection may be utilized to secure the cross bar to the supports beams of the storage rack system.

The cross bars of the present invention may be utilized individually, or in combination with one or more other of such cross bars, to span the beam supports within the storage rack system so that the single cross bar or combined cross bars serve to provide a generally surface upon which archival items may be stored for later retrieval. The configuration of the embodiments contemplated herein provide a more economic approach to bearing loads placed upon them over the prior art cross bars.

BRIEF DESCRIPTION OF THE FIGURES

The detailed description of some embodiments of the invention will be is made below with reference to the accompanying figures, wherein like numerals represent corresponding parts of the figures.

FIG. 1 shows various prior art embodiment of cross bars for spanning support beams in a shelving system;

FIG. 2 shows a perspective schematic view of one embodiment of the present invention;

FIG. 3 shows schematic end and side views of the embodiment of FIG. 2;

FIG. 4 shows placement of the embodiment on a generic storage rack system;

FIG. 5 shows a schematic view of another embodiment of the present invention supported on opposing beam supports of a storage rack system;

FIG. 6 shows a schematic side view of the embodiment of FIG. 5 secured to the beam supports via mechanical connectors.

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS

By way of example, and referring to FIGS. 2 and 3, one embodiment of an improved support system 110 comprises a cross bar 112 comprising a first generally flat section 114 and a second generally flat section 116, each comprising a surface 118 upon which items to be stored may be set. In this embodiment, integral with each surface 118 are flanges 120 that support the surfaces 118 of each generally flat section 114, 116 in a manner that permits significant weight bearing capacity. The generally flat sections 114, 116 need not be of any particular dimension, but may be tailored to suit the particular capacity desired. Likewise, the flanges 120 may be of any desired height corresponding to the load the cross bar 112 is intended to bear.

In one embodiment, the first and second generally flat sections 114, 116 are separated by a transition section 124 that links one flange 120 of the first generally flat section 114 with one flange 120 of the second generally flat section 116. In this embodiment, the transition 124 is configured to present a valley between the first and second generally flat sections 114, 116; i.e., the transition is configured so as to be positioned generally within a plane that is generally parallel to and spaced from the first surface of each of said generally flat members.

Preferably, the first and second generally flat sections 114, 116 comprises slotted openings 128 that serve to reduce the amount of material presented by the first and second generally flat sections 114, 116, while maintaining suitable stability and weight-bearing capacity. The slots 128 may be cut out of the surfaces 118 or punched through the surfaces. The specific size and shape of the slots 128 may be determined by the load the cross bar 112 is designed to carry when balanced against the amount of material necessary to sustain the load. Indeed, it may be desired to employ a plurality of more circular openings rather than slotted openings. Reducing weight while maintaining strength, however, is important to ensure suitable load-bearing effectiveness.

In one embodiment, cross bar 112 further comprises means for engaging a storage rack system, which in this embodiment comprises tabs 130 positioned in a manner that permits the cross bar 112 to be positioned on shelving support and minimize migration of the shelf. Referring to FIG. 4, one application of the embodiment 110 of FIGS. 2 and 3 comprises a storage rack system 210 comprising a first set of horizontal support beams 212 and a second set of horizontal support beams 214, each supported by posts 216. As can be appreciated, the combination of first and second set of horizontal support beams 212, 214, when affixed to posts 216, presents a frame upon which embodiments 110 of cross bars may be applied. In some cases, first horizontal support beam set 212 comprises a plurality of holes (not shown) into which the tabs 130 of cross bar embodiment 110 may be placed to preclude relative movement of the cross bar to the shelving support 210. In other cases, the user can elect to create holes in the horizontal support beams at locations unique to the layout of cross bars desired. In the support system embodiment shown in FIGS. 2 and 3, two tabs 130 are positioned at either end of the transition 124. However, it should be appreciated that more or less tabs may be used, and may be positioned at other places on the cross bar 112 as may be desired to engage a shelving system appropriately.

Referring to FIGS. 5 and 6, another embodiment of the inventive storage system comprises a cross bar 312 comprising a first generally flat section 314 and a second generally flat section 316, each comprising a surface 318 upon which items to be stored may be set. In this embodiment, integral with each surface 318 are flanges 320 that support the surfaces 318 of each generally flat section 314, 316 in a manner that permits significant weight bearing capacity. As with the first embodiment, the first and second generally flat sections 314, 316 are separated by a transition section 324 that links one flange 320 of the first generally flat section 314 with one flange 320 of the second generally flat section 316. Moreover, the first and second generally flat sections 314, 316 of this embodiment comprise a plurality of openings 328 that span across the first and second generally flat sections 314, 316. Again, the number, shape and size of the openings is not critical, as long as the cross bar 312 effectively supports the load it is intended to bear.

Spaced at opposing ends of the transition is a different means for engaging the cross bar 312 to a generic storage rack system. In FIGS. 5 and 6, a portion of a storage rack system comprises horizontal support beams 412 having an L-shaped cross-section with a shoulder upon which each end of the cross bar 312 may rest. In one embodiment, the means for engaging the cross bar 312 to the storage rack system comprises a pilot hole 330 positioned within the surface of the transition section 324. By employing a mechanical fastener, as shown in FIG. 6, the cross bar 312 may be effectively engaged with the horizontal support beam so as to minimize and hopefully eliminate movement of the cross bar 312 while any boxes (e.g., 500) are placed, moved or removed from the rack system.

The material that may be used for the cross bars of the present invention are not limited to any particular type of material, and may comprises one of various metals that have sufficient tensile and compressive load-bearing capabilities, including carbon steel, stainless steel, aluminum, etc. The cross bars may be manufactured by one of any number of available techniques that permit the formation of the configurations that present generally flat surfaces with openings as described herein.

A person of ordinary skill in the art should appreciate that the invention is not limited to the particular embodiments disclosed herein, but may reflect variations that embody the improved invention. For example, another embodiment may comprise three or more generally flat sections each separated by a transition section. Other variations are contemplated as well, such that the invention should be construed according to the claims as presented below. 

1. A cross bar for bearing a load across a span of distance between at least two horizontal supports in a storage system, the cross bar comprising first and second generally flat members each comprising a first surface configured to accept the placement of items for storage thereon, the cross bar further comprising a transition section between the first and second generally flat members, the flat members each comprising a plurality of openings to reduced the weight of the material used to manufacture the cross bar, wherein the transition section is defined by a generally flat second surface positioned generally within a plane that is generally parallel to and spaced from the first surface of each of said generally flat members.
 2. The cross bar of claim 1 further comprising means for engaging the cross bar to a storage rack system.
 3. The cross bar of claim 2 wherein the engaging means comprises pilot holes positioned on opposing ends of the transition section;
 4. The cross bar of claim 2 wherein the engaging means comprises tabs at a first and second end of said cross bar, wherein the tabs are configured to engage corresponding holes in horizontal supports in the storage system.
 5. The cross bar of claim 4, wherein the tabs are positioned at the transition section. 